Manufacture of decorative surfaces



Feb. 6, 1945. H. E. 'WALTER 2,369,092

MANUFACTURE OF DECORATIVE SURFACE Filed Jul 20, 1958 2 Sheets-Sheet 1 lmoentor C(ttorneg Feb. 6, 1945. H, E WALTER' 2,369,092

MANUFACTURE OF DECORATIVE SURFACE Filed July 20, 1938 2 Shets-Sheet 2 v w I 1 t r w Q Q J: J I I fvyezwar jferziyl? .Z/alier .Wfi {W 9M Patented Feb. 6, 1945 UNITED STATES-PATENT OFFICE MANUFACTURE vOF DECORATIVE SURFACES Henry E. Walter, Cloquet, Minn., assignor to Wood Conversion Company, Cloquet, Minn a corporation of Delaware Application July 20, 1938, Serial No. 220,355

2 Claims.

The present invention relates generally to marking temporarily plastic material in the process of manufacture to produce permanent mark: ings. It has particular reference to the manu facture of fibrous felts, such as thick paper or artificial board.

The particular object of the present invention is to produce intaglio impressions not of a definite pattern, butof a characteristic appearance in non-repetitive form; and to provide a means for that end.

The invention will be described with particular reference to artificial board made from an aqueous slurry of fibers, but it is to be understood, and it will be pointed out, that it has other applications; and that the device of theinvention, and

the manner of using it may vary considerably. Having reference to the accompanying drawings, the invention will be illustrated and explained as it' is applied in marking artificial board.

In .the drawings:

Fig. 1 is a reproduction of a photographed picture of the surface of a wall board panel made by the present invention. 4

Fig. 2 is a diagrammatic representation of the marking means.

Fig. 3 is an edge view more or less diagrammatic, of the means of Fig. 2. v

Fig. 4 is a longitudinal vertical section of a machinerfor continuously marking a continuously formed web of wallboard.

In order to attain a non-repetitive pattern the impression means is multiple and each elementis in part mobile and free to assume difierent positions. Each element is also in part constrained and fixed in part with respect to a carrier of the multiple elements, so that there is produced by the constraint, a general identity, or

. individual character in the design, and a pleasto the carrier between each two adjacent spaced points of attachment to the carrier, the looseness being due both to non-attachment to the carrier and to thecord or strand having a length greater than the distance measured in the carrier between adjacent points of attachment.

Therefore, whenthe carrier is taut, the strands are not taut, and they may assume any free position between the points of attachment.

I The carrier is one or more elements adapted to be pulled taut in one direction. The carrier is preferably a sheet backing. It may be afelt, or canvas, or rigid or flexible net, or merely be a plurality of parallel cords without lateral connections between them in the area used for impressions. The latter arrangement, and a coarse netting, can therefore be used in a taut position with varying widths coverable by the same backing, iving a finer or coarser pattern in the lateral direction.

The strands or cords maybe of fiber, such as rope, yarn or cord, or flexible wire or even rubber, and the latter may be smooth or marked, as desired. One strand, for example, may be attached to the backing at evenly spaced intervals in a straight line, running generally in the direction of the taut backing, or definitely angular to it, or in some irregular line. Other cords may have an, exactly similar attachment, and all points of attachment be arranged in parallel lines across the taut length. Some may be staggered with respect to others. -There may be strands across the taut length. These may be attached to the backing, or even be apart of the backing,

as where a coarse net is used, and not stretched.

laterally when it is pulled taut lengthwise.

. In other words, the character of the backing or the manner in which it is applied as a carrier, coupled with the pattern of the fixed 'points of attachment, is the means toprovide the desired character or general identity to .a design. The

manner in which the cords or'strands are free to assume difierent positions, is the cause of variation in the pattern, and the particular cause of a non-repetitivepattern.

In order to avoidshowing the many possible variations of the pattern, one illustrative. form isselected, which gives a pleasing efiect. In Fig. 2 there is shown a carrier which is a coarse net having a warp of heavy cords 10 adapted to be pulled taut to apply the carrier. Lighter weight transverse cords II are shown and at the intersections, any type of connection may be applied. When the net is expanded laterally to the full permissible width the transverse cords l I will be taut, but for the purpose of illustration the net is shown slightly contracted laterally with a taut warp, whereby the transverse cordsv between the warp cords are irregularly arranged, and will make a variable design where they may penetrate the plastic material.

J In Fig. 3 the diagrammatic block I: indicates the edge of alcarrier, and the single cord l3 thereon is representative of the strands which make .strands ill.

may be used as .the

the design. Cord i3 is shown with three spaced attachments l4, l5 and I6, of which l5 and I6 are points, while M is a length of cord l3 secured to carrier I2. On any carrier, the places of attachment, like I4 or l5, may be repetitive or non-repetitive in design. The repetitive design 'for attachment may be such as to give always an individual .characteristic to the resulting effect,

with uncontrollable variations from the loose parts. In Fig. 2, the-strands or cords are designated l1, and the .places of attachment are points I B, in a row across or otherwise disposed on the backing. Each strand I1 is shown with its series of spaced attachments alined, not in a straight line, but in staggered relation, with looseness of be merged without departing from the spirit and scope of the invention. For example, referring to Fig. 2, 'I' have described a taut set of strands in, and a loose set of strands l1. Both setsv may be identical strands. One or more strands may belong to set In. at one part of the structure to function as a carrier, and belong to set I! at another part of the structure to function as a mobile element. It is therefore to be understood-that the invention in its broadest aspect provides a marking structure which as a whole is capable of being pulled in a taut relation to fix the position of strand between adjacent points in the taut car'- rier. Thus the strands may fall into wavy lines generally, but not mathematically or regularly, or repeatedly. From the foregoing it is obvious how the arrangement may be varied.

Where the carrier or backing is a flexible sheet relatively closed, like canvas, the strands are located on the impressing surface thereof. But

where the carrier is more open, like a net, the

strands may be on either side thereof, or both sides. Where the strands cross the net on the non-impressing side, the cords of the net may be utilized as part of the impression means. Likewise, the cords of the net may function where they are exposed on the impression side, between Fig. 4. represents one way in which such an impression fabric may be used in a continuous ma.- chine for making artificial board.

Numeral indicatesa Fourdrinier or forming wire or'screen on which the wet fiber mat 21 is formed and on which it is yet quite plastic through the retention of water. This screen runs alon over supporting rolls 22, then-through a set of heavier press rolls 23 and 24, lighter press rolls 26 and 21, heavy squeeeze rolls 28 and 29, and a second set of squeeze rolls 30 and 3| .The wire returns over the lower roll 30, and the moist or damp fiber layer 32 is quites'elf-suppqrting, and ready to be dried. As the plastic mat 2| enters these rolls it receives on its top a stretch of an endless impression carrier 33 according to this invention, and an endless thick felt 36 which takes up water squeezed out. Rolls 3i, and 38 carry the felt as. Rolls 3|, 35, 31, 38, 39, and ii carry the impression blanket. Roll 39 depresses the blanket into washing tank 42, so'that it may scribed without departing from the invention. A separate carrier is preferred for many reasons.

.It is also to be understood that in many boardmaking'machines there is used a top-wire as well asthe lower forming-wire. The top-wire also carrier for the present invention. I v

It is further to be understood that I have described the invention in terms of "carrier and "loose elements in order to explain clearly thedifierent and specific functions. But it is to be understood that the elements and functions may the fixations of the mobile elements, so as to present mobileelements for self-positioning. The pattern designed, and the questions of construction with ease and economy determine the exact construction of the device.

It is of course to be'understood that a single length (not an endless belt) of impression blanket, may be used where a non-continuous process is used. For example, it may be used in the press shown in U. S. Ziska Patent No, 1,690,152, which .is used in an intermittent operation in making artificial board, serving at the same place as the press rolls above described.

Any board made by use of the above described 'marking device has a pleasing effect by reason of its non-repetitive pattern and other factors. The depth of depressions in the design are such as to cause visual shadows, and for this purpose should not be less than 0.q4 inch. The surface of the board presents the major portion of the high spots flattened to the same plane parallel with the opposite face of the board to give a uni- 5 form caliper to the board. These flattened high spots give high lights to contrast with said shadows. It is of course to be understood that the same method and impression material may be used in cement, plasterboard, gypsum board, and

40 other temporarily plastic body materials having a decorative surface. Theseare impressed while plastic, partially set to hold the impressions, and

then completely set after removal of the impression-making means.

i be cleaned of adherent fiber to assure clean im- The invention obviously is not limited to surfacing fiber boards, but may be used on any plastic material. Therefore the invention is broadly defined in the appended claims.

I claim:

1. An impression device for making intaglio designs in a plastic mass, comprising an open network carrier, and a multiplicity of strands carried by and over a face of said carrier, the

arrangement of various of the strands being characterized along the length of a strand by more than two spaced attachments to and along a dimension of the carrier, and relatively to the carrier by mobility and looseness between adjacent attachments when the carrier is applied to make an impression.

2. An impression device for making intaglio designs in a, plastic mass, comprising a flexible network carrier adapted to be pulled taut in at least one direction, and a multiplicity of strands carried by and over a face of said carrier, the

arrangement of various of the strands being characterized along the length of a strand by more than two spaced attachments to and along a dimension of the carrier, and relatively to the carrier by mobility and looseness between adjacent attachments when the carrier is taut in said direction. 7

HENRY E. WALTER. 

